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2003 KTM 525EXC - Clutch Push Rod Cover

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Hi,

My new to me 03 KTM 525EXC SuperMoto started leaking some oil recently on the left (stater) side.

After doing a little cleaning I found the clutch cover has a big gash in it, presumably from the chain (the chain has perfect tension). The cover is now streaming oil done the engine case bottom of where it is bolted to the engine.

I figure the best move is to lossen the cover, check the gasket/add some gasket goo, and reinstall.

My questions is -- what is the procedure for this? I have never worked on a hydraulic clutch before. How do I bleed the system after? What kind of "mineral oil" do I use?

Thanks for all your help!

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Edited by KnawJB
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You shouldn't have to bleed the clutch. Remove the slave cylinder and reseal everything, reinstall and you should be good to go.

Obviously your chain has hit the slave cylinder. It's not too uncommon with a 15T front sprocket on the RFS.

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Thanks for the help! I'm going to take off the cover tomorrow and hope for the best.

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